Artificial logs for fireplaces



April 1968 E. BRYAN I 3,377,229

ARTIFICIAL LOGS FOR FIREPLACES Filed Feb. 12, 1965 INVENTOR. LUTHER E.BRYAN BY WWW ATTORNEY 3,377,229 ARTlFlCIAL LOGS FOR FIREPLACES Luther E.Bryan, Sebring, Ohio, assignor to Gem Clay Forming, Ina, Sehring, Ohio,a corporation of Ohio Filed Feb. 12, 1965, er. No. 432,117 1 Claim. (Cl.16122) ABSTRACT F THE DISCLOSURE This invention relates to an artificiallog and more particularly to an artificial leg as used in a fireplace inthe presence of a burning gas.

This product employs refractory fibers molded into a desirable shape andreinforced by a fire clay preferably forming the visible surface of theartificial log. The refractory fibers are reinforced by organic andinorganic binders varied in proportions determined by temperature andstrength requirements.

It is the principal object of the invention to provide an artificialfireplace log of remarkably reduced weight as compared to a conventionalartificial fireplace log.

A further object of the invention is the provision of an artificialfireplace log which may be fabricated as a single unit having thedesirable appearance of the conventional fireplace log formed of clayand the like and capable of being used in a fireplace in the presence ofa gas flame in exactly the same manner as the conventional clayfireplace heretofore known in the art.

A still further object of the invention is the provision of anartificial log for a gas fireplace which has a relatively thin wallstructure and is thereby capable of being formed of a relatively smallquantity of refractory fibers so as to be economical in formation.

A still further object of the invention is the provision of anartificial log for a gas fireplace wherein the materials used in theformation of the log are light weight, capable of durable thin wallconstruction and more importantly able to withstand the temperaturesexperienced in the presence of gas flames and the like withoutdeterioration.

The artificial logs for gas fireplace heretofore known in the art havebeen formed of fire clay and shaped so as to resemble natural logs orsplit sections of natural logs and colored with suitable fire resistantpigments so that they very closely resemble such natural logs. Suchartificial logs as heretofore known in the art required relatively thickwall areas formed of relatively heavy fire clay or the like andtherefore weighed a considerable amount, which adversely affected thearea in which such artificial fireplace logs could 'be economicallyshipped.

The present invention discloses an artificial log for a gas fireplacewhich resembles a natural log, or a conventional fire clay artificiallog, and has the unique advantage of being extremely light in weight andtherefore capable of being shipped relatively long distances at aneconomical freight rate, thus very greatly increasing the distributionarea and the potential consumer demand with respect to the new articleof manufacture.

The artificial log for gas fireplaces disclosed herein makes it possibleto reduce the wall thickness of the conventional artificial log asheretofore formed of fire clay ite States Patent 0 3,377,229 PatentedApr. 9, 1968 and the like from 2 /2 or 3" as heretofore customary toapproximately /8", and the weight from approximately 25 pounds or moreto approximately 2 pounds more or less; thus, resulting in economics ofmanufacturing and shipping costs.

The artificial log for gas fireplaces as disclosed herein will despiteits thin wall, light weight construction withstand continuous usetemperatures as high as 2300 F. and will maintain its shape andappearance throughout temperature changes and resists spalling, crackingand other types of thermal shock.

With the foregoing and other objects in view which will appear as thedescription proceeds, the invention resides in the combination andarrangement of parts and in the details of construction hereinafterdescribed and claimed, it being the intention to cover all changes andmodifications of the example of the invention herein chosen for purposesof the disclosure, which do not constitute de partures from the spiritand scope of the invention.

The invention is illustrated in the accompanying drawing, wherein:

FIGURE 1 is a perspective View of a artificial log for gas fireplaceformed in accordance with the invention.

FIGURE 2 is a vertical section on line 22 of FIG- URE 1 and in enlargeddetail.

It will be understood from the following description that the artificiallog for a gas fireplace disclosed herein is a typical embodiment as theflexibility of the manufacturing process facilitates production of anartificial log of practically any required size and shape.

The preferred materials employed in manufacturing the artificial log fora gas fireplace are aluminum silicate fibers, a collodial silica primarybinder and a suitable organic secondary binder. A typical specificationfor the aluminum silicate fibers would be as follows:

Color White.

Fiber length Short to 1% inches.

Fiber diameter Submicron to 10 microns,

mean of 2 /2 microns.

Specific gravity 2.73.

Bulk density as shipped 4 lbs. per cubic foot. Recommended packingdensity 6 lbs. per cubic foot or higher. Use temperature Up to 2300 F.Melting point Above 3200 F.

The approximate chemical analysis of this material in percentage byweight is as follows:

Percent A1 0 51.2 SiO 47.4 B 0 0.7 N320 These fibers are placed in atank containing water and a colloidal silica which has the followingproperties:

Stability-Stable, except toward freezing which causes irreversibleprecipitation. Freezing point 32 F.

The silica is insoluble once the colloidal solution has dried. It alsohas the property of gel formation whereby small silica particles linktogether to form a strong aggregate structure.

3 In forming the artificial log for a gas fireplace, the initial shapeis formed of the aluminum silicate fibers and binders, as above noted,in a uniform and homogeneous structure wherein the fibers are disperseduniformly in the solution as set forth. A forarninous mold having anexterior surface conforming with the interior configuration of theartificial log is submerged in the solution which is drawn by vacuumthrough the mold causing the fibers to be deposited upon the moldsurface. The Wall thickness of the artificial log is determined by theamount of time that the mold is left submerged in the solution. The moldis then withdrawn from the solution and by means of vacuum theartificial log is removed from the mold and dried, whereupon it becomesa self-supporting unit.

The artificial log at this stage has satisfactory properties for itsintended use, but may not have desirable appearance characteristics, andit may not be susceptible to hand shaping and decorating, as iscustomary in the artificial log art.

By referring now to FIGURE 2 of the drawings, it will be seen that theartificial log is disclosed at this stage of production as a hollowshape, generally indicated by the numeral 10 and defining an elongatecavity 11 therein, which occurs between the bottom portion 12 thereofand the upper curving section 13 and the respective ends, one of whichapepars in FIGURE 2 and indicated by the numeral 14. A light-weight firebrick grog mixed with a clay and clay is then applied to the outermostsurface of the artificial log shape. As seen in FIGURE 2 of thedrawings, the layer of clay is indicated by the numeral 15. The layermay comprise a coating of from /s" to A" thick and in addition tocontributing to the properties of the artificial log, it provides asurface which may be mechanically or manually shaped and decorated sothat it very closely resembles a natural log, as may be seen byreferring to FIGURE 1 of the drawings.

In the formation of artificial logs for gas fireplaces, it is customaryto shape the visible surface by hand so as to impart realistic appearingcharacteristics, such as splits in the bark, details of the bark and thedetails at the ends of the logs which resemble sawed or split sections.In addition to the formation of the artificial logs for gas fireplacesfrom aluminum silicate fibers and the colloidal silica binder, it isalso possible to utilize fibers of mineral Wool, asbestos and otherfibers, as will occur to those skilled in the art, together with otherbinders both organic and inorganic.

In a preferred embodiment, the aluminum silicate fibers are present asapproximately 90% of the initially formed shape as illustrated in thedrawings and indicated by the numeral 13. The artificial log afterhaving been manually finished as to shape and appearance is then coloredwith suitable colors of suitable pigment so that the portions of the logthat resemble bark have natural coloration; those portions whichresemble the cut or split wood beneath the bark are coloredappropriately; and the completed artificial log is then driedthoroughly, which completes its fabrication, and. the same is ready forinstallation in a fireplace where gas flames can be directed under, onand around it as desired and where it will maintain its shape andappearance indefinitely.

It will occur to those skilled in the art that an artificial log for agas fireplace has many of the characteristics of a clay radiant in thatthe material of the log becomes heated by the gas flames to atemperature where the heat is radiated and the artificial log disclosedherein is particularly suitable for such function as it is capable ofbeing subjected to operating temperatures up to 2300 F. It has highresistance to thermal shock, such as cracking and spalling, and ittherefore contributes to combustion efficiency of the gas flamesdirected thereagainst when the same has been heated, all of which ishighly desirable in an artificial log for a gas fireplace.

Artificial logs for gas fireplaces manufactured with the foregoingmaterials and method are light in weight, adaptable to size and shape,they are stable, thin walled, easy to install or replace and offer theincidental economic advantages While providing an improved product.

It will thus be seen that an artificial log for gas fireplaces has beendisclosed, which meets the several objects of the invention and havingthus described my invention what I claim is:

1. An artificial log comprising an inner supporting structure ofaluminum silicate fibers, in predominate proportion, held in a stableself-supporting structural shape by an inorganic refractory colloidalbinder of silica gel which makes up the balance of the mixture, saidstructure comprising a base portion and a convexly curved upwardlyextending portion, the outer surface of said upwardly extending portioncarrying a relatively thin layer of clay, said clay being a light-Weightfire brick grog mixed with a clay binder and pigment and shaped tosimulate an artificial log.

References Cited UNITED STATES PATENTS 2,684,566 6/ 1937 Warfield158-100 3,231,401 1/1966 Price et al 1 0657 3,253,936 5/1966 Weindel10664 JACOB H. STEINBERG, Primary Examiner.

